CN115193180A

CN115193180A - Filter medium, filter medium pack and filter element

Info

Publication number: CN115193180A
Application number: CN202210671509.3A
Authority: CN
Inventors: D·E·阿达梅克; S·M·布朗; M·A·萨拉
Original assignee: Donaldson Co Inc
Current assignee: Donaldson Co Inc
Priority date: 2016-12-12
Filing date: 2017-12-12
Publication date: 2022-10-18
Also published as: WO2018111923A1; BR112019011544A2; RU2019118897A; RU2019118897A3; MX2019006625A; JP7398956B2; CN110267726B; EP3551316A1; CN110267726A; RU2749791C2; US20180161717A1; JP2024009890A; BR112019011544B1; JP2020500696A

Abstract

Embodiments include an air filtration media pack comprising a plurality of layers of fluted media, each layer comprising a facing sheet and a fluted sheet, the fluted sheet comprising a first plurality of flutes and a second plurality of flutes arranged in a parallel flow configuration; wherein the first and second plurality of flutes exhibit a regularly repeating difference in flute shape, flute size, flute height, flute width, flute cross-sectional area, or filter media.

Description

Filter medium, filter medium pack and filter element

This application is based on the applicant of all countries, the american national Company donason ltd (Donaldson Company, inc.) and the applicant of all countries, the american national denier E-ada Mei Ke (Daniel e.adame); national scott.m. Brown (Scott m.brown); and PCT international application filed on 12.12.2017 in the name of citizen Mark a sala (Mark a. Sala), and claiming priority from U.S. provisional application No. 62/433,145 filed on 12.12.2016, the contents of which are incorporated herein by reference in their entirety.

Technical Field

Embodiments herein relate to filter media, filter media packs, filter elements, air cleaners, and methods of making and using filter media, media packs, elements, and air cleaners. More particularly, embodiments herein relate to z-flow filtration media, media packs, and filter elements.

Background

Z-flow filtration media such as that described in U.S. patent No. 7,959,702 to inventor Rocklitz (Rocklitz) has multiple layers of media. Each layer has a fluted sheet, a facing sheet, and a plurality of flutes extending from the first face to the second face of the filter media pack. A first portion of the plurality of flutes are closed to unfiltered air flowing into the first portion of the plurality of flutes, and a second portion of the plurality of flutes are closed to unfiltered air flowing out of the second portion of the plurality of flutes. Air entering the flutes on one face of the media pack passes through the filter media before exiting the flutes on the other face of the media pack.

Despite the many benefits of z-flow media, there remains a need for improved filtration performance, including filtration media, media packs, and elements having reduced pressure loss across the element and/or improved particulate loading capability.

Disclosure of Invention

The present application relates to filter media, filter media packs, filter elements, and air cleaners having two or more different media configurations, and methods of making and using the same. The different media configurations may be, for example, different slot geometries in z-flow filter media. The use of two or more different media configurations allows for improved performance, such as reduced pressure loss and/or increased load capacity, relative to the use of a single media configuration.

In an exemplary implementation, two different media portions are combined into a single filter element, the two media portions having different pressure loss and load characteristics. The difference in pressure loss and load characteristics between the media portions is typically less than the normal variation observed from manufacturing variations in the filter element, so the difference will typically be at least 5% for a particular measured and varied parameter, and more typically at least 10% for a particular measured and varied parameter.

In an exemplary configuration, the first media portion has a lower initial pressure loss than the second media portion, and the second media portion has a greater dust holding capacity than the first media portion. In some configurations, the combination of the two media portions results in an element with better performance than that achieved by a media pack made from only one of the media alone and better performance than that achieved by averaging the performance of each media portion alone. Thus, the hybrid filter element may, for example, exhibit reduced initial pressure loss, but also exhibit increased loading, relative to a media pack made with only one media or the other.

For example, the slot heights may be varied such that each layer of media has a varying height, multiple layers of media have different heights, or larger portions of media have different heights.

The flow of the medium through these different layers and portions is typically a parallel flow. As used herein, the term "parallel" refers to a configuration in which the fluid stream to be filtered is dispersed into a first plurality of troughs and a second plurality of troughs and then typically reconverged. Thus, "parallel" does not require that the slots themselves be arranged in a geometrically parallel configuration (although they are often so arranged), but that the plurality of slots exhibit parallel flow with respect to one another. Thus, a "parallel" flow is in contrast to a "serial" flow (where in a serial flow, the flow comes from one plurality of slots and then enters a second plurality of slots).

Structures made in accordance with the present disclosure may, for example, allow for improved pressure loss and dust loading relative to filter media packs and elements made from a single media type. In addition, in some implementations, more media can be added to a specified volume without significantly increasing the initial pressure loss. In this way, a media structure can be produced that has a relatively low initial pressure loss while still having a relatively high dust loading capacity. This improvement can be obtained by combining a first medium with a low initial pressure loss (but low dust loading capacity) with a second medium with a higher initial pressure loss (and higher dust loading capacity). In some embodiments, the resulting combined media exhibits an initial pressure loss similar to the first media but with a dust load of the second media.

The benefits of the mixed media structure can also be exploited to achieve more media in a given volume and more dust loading on a given media surface area. Thus, improved media performance can be achieved while having less media.

In exemplary constructions, the first media pack can comprise, for example, about 10%, 20%, 30%, 40%, 50%, 60%, 70%, 80%, or 90% of the media pack (measured in volume); and the second media pack can comprise, for example, about 10%, 20%, 30%, 40%, 50%, 60%, 70%, 80%, or 90% of the media pack (measured in bag volume). As used herein, the enclosure volume means the total volume occupied by the media pack when measuring the area contained within the perimeter of the pack. Thus, the bag volume can include the media itself, as well as the open upstream volume into which dust can be loaded and the downstream volume through which filtered air flows out of the media pack. Alternatively, the first plurality of slots comprises 20% to 40% of the package volume and the second plurality of slots comprises 60% to 80% of the package volume. In other implementations, the first plurality of slots constitutes 40% to 60% of the package volume and the second plurality of slots constitutes 60% to 40% of the package volume. In yet another implementation, the first plurality of flutes comprise 60% to 90% of the inlet face of the media pack and the second plurality of flutes comprise 40% to 10% of the pack volume.

In such exemplary constructions, the first media pack can be, for example, about 10%, 20%, 30%, 40%, 50%, 60%, 70%, 80%, or 90% of the media pack (measured as media surface area); and the second media pack can be, for example, about 10%, 20%, 30%, 40%, 50%, 60%, 70%, 80%, or 90% of the media pack (measured as media surface area). As used herein, pack surface area means the total surface area of media in each media pack with the media pack disassembled and the media stretched apart. Alternatively, the first plurality of flutes constitute 20% to 40% of the media surface area and the second plurality of flutes constitute 60% to 80% of the media surface area. In other implementations, the first plurality of flutes comprise 40% to 60% of the inlet face of the media surface area and the second plurality of flutes comprise 60% to 40% of the media surface area pack. In yet another implementation, the first plurality of flutes comprise 60% to 90% of the media surface area and the second plurality of flutes comprise 40% to 10% of the media surface area. The media pack may also be characterized by the portion of the inlet face occupied by a particular media type. In some implementations, the first media pack (including the first plurality of flutes) constitutes 10% to 90% of the inlet face of the media pack, such as 10%, 20%, 30%, 40%, 50%, 60%, 70%, 80%, or 90% of the inlet face of the media pack; and the second media pack (including the second plurality of flutes) constitutes 90% to 10% of the inlet face of the media pack, such as 90%, 80%, 70%, 60%, 50%, 40%, 30%, 20%, or 10% of the inlet face of the media pack. Alternatively, the first plurality of flutes comprise 20% to 40% of the inlet face of the media pack and the second plurality of flutes comprise 60% to 80% of the inlet face of the media pack. In other implementations, the first plurality of flutes comprise 40% to 60% of the inlet face of the media pack and the second plurality of flutes comprise 60% to 40% of the inlet face of the media pack. In yet another implementation, the first plurality of flutes comprise 60% to 90% of the inlet face of the media pack and the second plurality of flutes comprise 40% to 10% of the inlet face of the media pack.

Another embodiment of a filter media pack includes a third plurality of flutes arranged in parallel flow with the first plurality of flutes and the second plurality of flutes; wherein the first, second, and third pluralities of flutes exhibit regularly repeating differences in flute shape, flute size, flute height, flute width, flute cross-sectional area, or filter media. Optionally, each of the first, second and third pluralities of slots are arranged in separate pluralities of layers. It should be understood that in some implementations, more than three of the plurality of flutes are arranged in parallel flow, wherein each of the plurality of flutes exhibit differences in flute shape, flute size, flute height, flute width, flute cross-sectional area, or filter media. Typically, these differences in slot characteristics are repetitive, often regularly repetitive.

In an exemplary configuration having three types of flutes, the first flute, the second flute, and the third flute may be selected such that the first plurality of flutes constitute 20% to 50% of the volume of the media pack, such as 20%, 30%, 40%, or 50% of the volume of the media pack; the second plurality of flutes comprise 20% to 50% of the volume of the pack, such as 20%, 30%, 40%, or 50% of the volume of the media pack; and the third plurality of flutes constitutes 20% to 50% of the volume of the media pack, such as 20%, 30%, 40%, or 50% of the volume of the media pack.

In an exemplary structure having three types of flutes, the first flutes, second flutes, and third flutes can be selected such that the first plurality of flutes comprise 20% to 50% of the media surface area of the media pack, such as 20%, 30%, 40%, or 50% of the media surface area of the filter media pack; the second plurality of flutes comprise 20% to 50% of the media surface area of the media pack, such as 20%, 30%, 40%, or 50% of the media surface area of the media pack; and the third plurality of flutes comprise 20% to 50% of the media surface area of the media pack, such as 20%, 30%, 40%, or 50% of the surface area of the media pack.

In an exemplary structure having three types of flutes, the first flute, the second flute, and the third flute may be selected such that the first plurality of flutes constitute 20% to 50% of the inlet face of the media pack, such as 20%, 30%, 40%, or 50% of the inlet face of the filter media pack; the second plurality of flutes comprise 20% to 50% of the inlet face of the media pack, such as 20%, 30%, 40%, or 50% of the inlet face of the filter media pack; and the third plurality of flutes constitute 20% to 50% of the inlet face of the media pack, such as 20%, 30%, 40%, or 50% of the inlet face of the media pack.

An exemplary air filtration media pack has multiple layers of fluted z-flow media. In some constructions, each layer of media has a facing sheet and a fluted sheet. Each fluted sheet includes a plurality of flutes that exhibit regularly repeating differences in flute shape, flute size, flute height, flute width, flute cross-sectional area, or filter media. The plurality of slots are arranged in a parallel flow pattern. The facing sheet may, for example, be composed of the same material that forms the fluted sheet, or may be composed of a different material. The facing sheet is typically not grooved, but may be grooved in some constructions. The facing sheet may have filtering properties or be a non-filtering material (such as a spacer material) that does not have filtering properties. Additionally, the facing sheet may cover all or only a portion of each fluted sheet. The facing sheet may be continuous or segmented such that individual facing sheet segments are positioned against each facing sheet.

The different media types in the plurality of flutes are in parallel flow with each other. As described above, the term "parallel" as used herein refers to a configuration in which the fluid streams to be filtered are dispersed into a first plurality of troughs and a second plurality of troughs and then typically converge again. Thus, "parallel" does not require that the slots themselves be arranged in a geometrically parallel configuration (although they are often so arranged), but that the plurality of slots have a generally parallel flow with respect to each other. Thus, a "parallel" flow is in contrast to a "serial" flow, where the flow comes from one plurality of slots and then enters a second plurality of slots. It should be understood that in some constructions, such as a wrap construction, the fluid flow may be between adjacent portions of the filter media.

The media may be arranged in various configurations within the media pack, including alternating single-sided layers (e.g., configurations A/B/C/A/B/C., where A, B and C each refer to a different slot type, and "/" refers to separate layers.

The use of the terms "a", "B" and "C" slots is meant to represent media having different properties. For example, the a-groove may have a higher height than the B-groove or the C-groove; or the B-shaped groove can have a width larger or smaller than that of the A-shaped groove or the C-shaped groove; or the a-grooves may be formed of a media having a higher efficiency and/or permeability than the B-grooves or the C-grooves.

It should also be understood that the media may be arranged in a configuration in which slot-like layers are grouped together, such as a media pack having the configuration A/A/A/B/B/B/C/C/C. In this configuration, there are four layers with a slots, three layers with B slots, and three layers with C slots. Each of the layers of the type having slots A, B and C are grouped together. Different media regions containing different types of slots may be in direct contact with one another, such as by being arranged in a stacked or wrapped configuration. They are also arranged so that different media regions are separated by partitions or other components.

It should also be understood that there may be more than three or four layers of similar slots grouped together, depending on slot size, media pack size, etc. The media pack may be constructed with multiple layers of each media, such as, for example, ten, twenty, thirty, or forty layer grouped a slots; or ten, twenty, thirty, or forty layer grouped B slots, etc.

In some configurations, the grooves may vary repeatedly within a layer and between layers. For example, a media pack having the structure abc./def./abc./def.. Causes layers having repeating troughs a, B, and C to alternate with layers having troughs D, E, and F. Other examples are not limited to including media packs having an ab./cdef./ab./CDEF; a media pack having a./bcd./a./bcd.

The use of more than one slot configuration within a given filter media pack or air cleaner may provide various benefits, including having a lower initial limit of one slot configuration and dust holding capacity of a second slot configuration. Thus, an element formed from the combined media may outperform an element formed from only one slot configuration. Combining different types and styles of slot geometries in this manner allows for improvements in one or more of cost, initial pressure loss, load capacity, or other aspects of filtration performance.

In some configurations, the relative position of the media is determined by the desired characteristics of the elements. For example, due to the air cleaner in which the filter element is placed, a higher permeability media may be arranged in the region of the filter element with the highest head-on velocity to reduce the initial restriction. In other embodiments, a higher efficiency media is arranged in the region with the highest head-on velocity to increase the initial efficiency of the filter element.

This summary is an overview of some of the teachings of the present patent application and is not intended to be an exclusive or exhaustive treatment of the present subject matter. Further details can be found in the detailed description and the appended claims. Other aspects will become apparent to those skilled in the art upon reading and understanding the following detailed description and review of the drawings that form a part hereof, and are not to be considered in a limiting sense. The scope herein is defined by the appended claims and their legal equivalents.

Drawings

Aspects may be more fully understood in conjunction with the following drawings, in which:

FIG. 1 is a perspective view of an exemplary filter element according to an exemplary embodiment.

Fig. 2A is an enlarged schematic cross-sectional view of a cross-section of a filter media.

FIG. 2B is an enlarged partial cross-sectional view of a sheet of fluted medium and top and bottom facing sheets.

FIG. 3 is a top schematic view of an exemplary filter media pack, showing a coiled configuration with two types of filter media.

FIG. 4 is a top schematic view of an exemplary filter media pack showing a coiled configuration with three types of filter media.

FIG. 5 is a top schematic view of an exemplary filter media pack, illustrating a stacked configuration of filter media.

FIG. 6 is a top schematic view of an exemplary filter media pack, illustrating a stacked configuration of filter media.

FIG. 7 is a top schematic view of an exemplary filter media pack, illustrating a stacked configuration of filter media.

FIG. 8 is a top schematic view of an exemplary filter media pack showing a stacked configuration with three types of filter media.

FIG. 9 is a top schematic view of an exemplary filter media pack, illustrating a stacked configuration with two types of filter media.

FIG. 10 is a top schematic view of an exemplary filter media pack, showing a stacked configuration with two types of filter media.

FIG. 11 is a top schematic view of an exemplary filter media pack, illustrating a stacked configuration with two types of filter media.

FIG. 12 is a top schematic view of an exemplary filter media pack, showing a stacked configuration with two types of filter media.

FIG. 13 is a top schematic view of an exemplary filter media pack, showing a stacked configuration with two types of filter media.

FIG. 14 is a top schematic view of an exemplary filter media pack showing a stacked configuration with three types of filter media.

FIG. 15 is a top schematic view of an exemplary filter media pack showing a coiled configuration with two types of filter media.

FIG. 16 is a top schematic view of an exemplary filter media pack showing a coiled configuration with three types of filter media.

FIG. 17 is a top schematic view of an exemplary filter media pack showing a stacked configuration with three types of filter media.

FIG. 18 is a top schematic view of an exemplary filter media pack, showing a stacked configuration with two types of filter media.

FIG. 19 is a top schematic view of an exemplary filter media pack, showing a stacked configuration with two types of filter media.

FIG. 20 is a top schematic view of an exemplary filter media pack, showing a stacked configuration with two types of filter media.

FIG. 21 is a top schematic view of an exemplary filter media pack, showing a stacked configuration with two types of filter media.

FIG. 22 is a top schematic view of an exemplary filter media pack showing a stacked configuration with two types of filter media.

FIG. 23 is a top schematic view of an exemplary filter media pack showing a stacked configuration with three types of filter media.

FIG. 24A is a top schematic view of an exemplary filter media pack, showing a coiled configuration with two types of filter media.

FIG. 24B is a top schematic view of an exemplary filter media pack, showing a coiled configuration with two types of filter media.

FIG. 25A is a top schematic view of an exemplary filter media pack showing a coiled configuration with three types of filter media.

FIG. 25B is a top schematic view of an exemplary filter media pack, showing a coiled configuration with three types of filter media.

FIG. 26A is a top schematic view of an exemplary filter media pack, showing a coiled configuration with two types of filter media.

FIG. 26B is a top schematic view of an exemplary filter media pack, showing a coiled configuration with two types of filter media.

Fig. 27 shows performance results of comparative testing of filter elements having different media types.

Fig. 28A and 28B show performance results for various media configurations, including dust loading and pressure loss.

Fig. 29A and 29B show performance results for various media configurations, including dust loading and pressure loss.

Fig. 30A and 30B show performance results for various media configurations, including dust loading and pressure loss.

While the embodiments are susceptible to various modifications and alternative forms, specifics thereof have been shown by way of example and drawings and will be described in detail. It should be understood, however, that the scope of this document is not limited to the described embodiments. On the contrary, the invention is to cover modifications, equivalents, and alternatives falling within the spirit and scope of the invention.

Detailed Description

In an exemplary embodiment, the present application relates to an air filtration media pack comprising a plurality of layers of fluted media, each layer comprising a first plurality of flutes and a second plurality of flutes arranged in a parallel flow configuration; wherein the first plurality of flutes and the second plurality of flutes exhibit differences in flute shape, flute size, flute height, flute width, flute cross-sectional area, or filter media.

These multiple slots are arranged in parallel flow. As noted above, as used in this context, the term "parallel" refers to a configuration in which the fluid streams to be filtered are dispersed into a first plurality of troughs and a second plurality of troughs and then typically converge again. Thus, "parallel" does not require that the slots themselves be arranged in a geometrically parallel configuration (although they are often so arranged), but that the plurality of slots exhibit parallel flow with respect to one another. Thus, a "parallel" flow is in contrast to a "serial" flow (where in a serial flow, the flow comes from one plurality of slots and then enters a second plurality of slots).

In some implementations, the filter media pack can be constructed such that the first and second pluralities of flutes are arranged together within at least one layer of fluted media. In other implementations, the first plurality of slots is arranged in a first plurality of layers and the second plurality of slots is arranged in a second plurality of layers of slotted media. The two structures may also be combined such that each layer has repeated differences between the slots and different layers are combined.

In an exemplary implementation, two different media packs having different pressure loss and load characteristics are combined into a single filter element. In an example, the first media pack has a lower initial pressure loss than the second media pack, and the second media pack has a greater dust holding capacity than the first media pack. In some configurations, the combination of these two media results in an element with better performance than achieved with either media alone and better performance than achieved by averaging the performance of each media pack alone. Thus, the hybrid filter element may, for example, exhibit a reduced initial pressure flow, but also exhibit an increased load.

In exemplary configurations, the first media pack can be, for example, about 20%, 30%, 40%, or 50% of the media pack (measured in volume of the bag); and the second media pack can be, for example, about 20%, 30%, 40%, or 50% of the media pack (measured in volume of the bag). As used herein, the enclosure volume means the total volume occupied by the media pack when measuring the area contained within the perimeter of the pack. Thus, the enclosure volume can include the media itself, as well as the open volume into which the dust can be loaded.

In such exemplary constructions, the first media pack may be, for example, about 20%, 30%, 40%, or 50% of the media pack (measured as media surface area); and the second media pack may be, for example, about 20%, 30%, 40%, or 50% of the media pack (measured as media surface area). As used herein, pack surface area means the total surface area of media in each media pack with the media pack disassembled and the media stretched apart.

In some implementations, the first plurality of flutes constitute from 10% to 90% of the inlet face of the media pack and the second plurality of flutes constitute from 90% to 10% of the inlet face of the media pack. Alternatively, the first plurality of flutes comprise 20% to 40% of the inlet face of the media pack and the second plurality of flutes comprise 60% to 80% of the inlet face of the media pack. In other implementations, the first plurality of flutes comprise 40% to 60% of the inlet face of the media pack and the second plurality of flutes comprise 60% to 40% of the inlet face of the media pack. In yet another implementation, the first plurality of flutes comprise 60% to 90% of the inlet face of the media pack and the second plurality of flutes comprise 40% to 10% of the inlet face of the media pack.

Another embodiment of a filter media pack includes a third plurality of flutes arranged in parallel flow with the first and second plurality of flutes; wherein the first plurality of flutes, the second plurality of flutes, and the third plurality of flutes exhibit regularly repeating differences in flute shape, flute size, flute height, flute width, flute cross-sectional area, or filter media. Optionally, each of the first, second and third pluralities of slots are arranged in separate pluralities of layers. It should be understood that in some implementations, more than three of the plurality of flutes are arranged in parallel flow, wherein each of the plurality of flutes exhibits a regular repeating difference in flute shape, flute size, flute height, flute width, flute cross-sectional area, or filter media.

In an exemplary configuration having three types of flutes, the first flute, the second flute, and the third flute can be selected such that the first plurality of flutes comprise 30% to 50% of the inlet face of the media pack; the second plurality of flutes comprise 20% to 40% of the inlet face of the media pack; and the third plurality of flutes comprise 20% to 40% of the inlet face of the media pack.

In another exemplary configuration having three types of flutes, the first flute, the second flute, and the third flute may be selected such that the first plurality of flutes comprise 50% to 70% of the inlet face of the media pack; the second plurality of flutes comprise 10% to 30% of the inlet face of the media pack; and the third plurality of flutes comprise 10% to 30% of the inlet face of the media pack.

In some implementations, the multiple layers of single facer media are arranged in a rolled configuration, while in other implementations, the facer media are arranged in a stacked configuration.

In some configurations, the first and second pluralities of single facer media are arranged in a hybrid configuration, wherein the one or more layers of the first plurality of single facer media alternate with the one or more layers of the second plurality of single facer media. In an exemplary implementation having at least three types of single facer media, the first and second plurality of layers of single facer media are arranged in a hybrid configuration, wherein the one or more layers of the first plurality of single facer media alternate with the one or more layers of the second plurality of single facer media and the one or more layers of the third plurality of single facer media. Additionally, when three types of media are used, the first, second, and third multi-layer single facer media are arranged in a blended configuration, wherein the one or more layers of the first plurality of single facer media alternate with the one or more layers of the second plurality of single facer media and the one or more layers of the third plurality of single facer media. In some implementations, more than three types of filter media are used, and these different types of media may be combined in a mixed manner or in a polymerized manner, where the different types of media are collected together without mixing between media types. Alternatively, the media may be aggregated into smaller groups and then mixed, such as by one media having five layers and a different media having three layers.

Referring now to the drawings, other aspects of the filter media, media pack, and elements will be identified.

First, with respect to FIG. 1, a perspective view of an exemplary filter element 10 is shown. The exemplary filter element 10 includes an inlet 12, an outlet 14 on a side of the element 10 opposite the inlet 12, and a coiled z-flow media 20 within the element 10. A seal 30 is shown surrounding the inlet 12 and a support frame 40 is depicted. It should also be understood that the filter element may have a reverse flow to that shown in fig. 1, such that the inlet 12 and outlet 14 are reversed.

Fig. 2A is an enlarged schematic cross-sectional view of a cross-section of a single facer filter media 200 suitable for use in a filter media pack and filter element as described herein. The single facer media 200 includes a fluted sheet 210, and a top facing sheet 220 and a bottom facing sheet 230. The fluted sheet 210 includes a plurality of flutes 250. A fluid stream to be filtered (such as air for an internal combustion engine) enters the slots 250 along a flow path 260 and then travels along the slots until passing through the filter media and out of the different slots along a fluid flow path 270. Such fluid flow through a fluted media pack is described, for example, in U.S. patent No. 7,99,702 to Rocklitz, which is incorporated herein by reference in its entirety.

Fig. 2B is an enlarged front view of a sheet of fluted media having a fluted sheet 280, a top facing sheet 282, and a facing media 284 constructed and arranged in accordance with an embodiment of the invention, illustrating example flute dimensions. Grooved sheet 280 includes grooves 281. In the depicted embodiment, the slot 281 has a width A measured from a first peak to an adjacent peak. In an exemplary embodiment, the width a is 0.75 to 0.125 inches, alternatively 0.5 to 0.25 inches, and alternatively 0.45 to 0.3 inches. The slot 281 also has a height B measured from adjacent like-sized peaks. The slot 281 has an area between the slotted sheet 281 and the facing sheet 282 measured perpendicular to the slot length. The area may vary depending on the length of the slot as the height, width or shape of the slot varies along its length, such as when the slot is tapered.

FIG. 3 is a top schematic view of an exemplary filter media pack 300 for a filter element. The filter media pack 300 has two types of filter media: a first medium 310 and a second medium 320. The media is shown in a coiled configuration, where the two types of filter media are mixed and overlapped. The

filter media

310 and 320 are shown in schematic form without the actual flutes of the media. The filter media pack 300 may typically be formed by simultaneously winding different types of media around a central axis. In this exemplary embodiment, the ratio of the surface areas of

media

310 and 320 is about 1:1.

FIG. 4 is a top schematic view of an exemplary filter media pack 400, showing a coiled configuration with three types of filter media. The filter media pack 400 has three types of filter media: a first medium 410, a second medium 420, and a third medium 430. The media is shown in a coiled configuration, where three types of filter media are mixed and overlapped. The

filter media

410, 420, and 430 are shown in schematic form, without the actual flutes of the media. The filter media pack 430 may typically be formed by simultaneously winding three different types of media around a central axis. In this exemplary embodiment, the ratio of the surface areas of

media

410 and 420 and 430 is about 1.

Fig. 5 is a top schematic view of an exemplary filter media pack 500, showing a stacked configuration with two types of flutes. The filter media pack 500 has two types of flutes: a first groove 510 and a second groove 520.

FIG. 6 is a top schematic view of an exemplary filter media pack 600 illustrating a stacked configuration with different types of filter media. The filter media pack 600 has three types of flutes: a first slot 610, a second slot 620, and a third slot 630.

FIG. 7 is a top schematic view of an exemplary filter media pack 700, illustrating a stacked configuration with different types of flutes. The filter media pack 710 has two types of flutes: a first slot 710 and a second slot 720.

FIG. 8 is a top schematic view of an exemplary filter media pack 800 illustrating a stacked configuration with three types of filter media. The three types of filter media are first media 810, second media 820, and third media 830. The media are shown in a stacked configuration, with the three types of filter media separated by media type without mixing. In this exemplary embodiment, the ratio of filter media 810 to 820 and 830 is about 4.

Fig. 9 is a top schematic view of an exemplary filter media pack 900, showing a stacked configuration with two types of filter media: a first medium 910 and a second medium 920. The media is shown in a stacked configuration, where the two types of filter media are separated without mixing. In this exemplary embodiment, the ratio of filter media 910 to 920 is approximately 1:1 based on the total packet entry area.

FIG. 10 is a top schematic view of an exemplary filter media pack 1000, showing a stacked configuration with two types of filter media: a first media 1010 and a second media 1020. The media is shown in a stacked configuration. In this exemplary embodiment, the ratio of filter media 1010 to 1020 is about 9:1 based on the total packet entry area.

FIG. 11 is a top schematic view of an exemplary filter media pack, illustrating a stacked configuration with two types of filter media. The filter media pack 1100 has two types of filter media: a first medium 1110 and a second medium 1120.

Media

1110 and 1120 are stacked with five layers of filter media 1110 alternating with two layers of media 1120.

FIG. 12 is a top schematic view of an exemplary filter media pack, showing a stacked configuration with two types of filter media. The filter media pack 1200 has two types of filter media: a first medium 1210 and a second medium 1220. The media is shown in a stacked configuration. The

media

1210 and 1220 are stacked with two layers of filter media 1210 alternating with one layer of media 1220.

Fig. 13 is a top schematic view of an exemplary filter media pack 1300, showing a stacked configuration with two types of filter media. The filter media pack 1300 has two types of filter media: a first medium 1310 and a second medium 1320.

Media

1310 and 1320 are stacked, with one layer of filter media 1310 alternating with one layer of media 1320.

Fig. 14 is a top schematic view of an exemplary filter media pack 1400. The filter media pack 1400 has three types of filter media: first medium 1410, second medium 1420, and third medium 1430.

Dielectric layers

1410, 1420, and 1430 are arranged in alternating stacks.

Fig. 15 is a top schematic view of an exemplary filter media pack 1500, showing a coiled configuration with two types of

filter media

1510 and 1520. The media is rolled with the first media 1510 on the inside and the second media 1520 on the outside, the first media 1510 and the second media 1520 spliced together.

FIG. 16 is a top schematic view of an exemplary filter media pack 1600 showing a coiled configuration with three types of

filter media

1610, 1620, and 1630. The media is rolled with the first media 1610 on the inside, the second media 1620 in the middle, and the third media 1630 on the outside. The first medium 1610 is spliced to the second medium 1620, and the second medium 1620 is spliced to the third medium 1630.

FIG. 17 is a top partially schematic view of an exemplary filter media pack 1700 showing a stacked configuration with three types of filter media. The three types of filter media are a first media 1710, a second media 1720, and a third media 1730. The media is shown in a stacked configuration, with three types of filter media separated by media type without mixing. In this exemplary embodiment, the ratio of filter media 1710 to 1720 to 1730 based on total packet entry area is about 4.

FIG. 18 is a top schematic view of an exemplary filter media pack 1800 showing a stacked configuration with two types of filter media: a first medium 1810 and a second medium 1820. The media are shown in a stacked configuration with two types of filter media separated. In this exemplary embodiment, the ratio of filter media 1810 to 1820 is approximately 1:1 based on the total packet entry area.

FIG. 19 is a top schematic view of an exemplary filter media pack 1900 showing a stacked configuration with two types of filter media. The filter media pack 1900 has two types of filter media: a first media 1910 and a second media 1920. The media is shown in a stacked configuration. In this exemplary embodiment, the ratio of filter media 1910 to 1920 is approximately 9:1 based on the total packet entry area.

FIG. 20 is a top schematic view of an exemplary filter media pack 2000, showing a stacked configuration with two types of filter media. The filter media pack 2000 has two types of filter media: a first medium 2010 and a second medium 2020. The media pack 2000 has six layers of filter media 2010 alternating with two layers of media 2020.

Fig. 21 is a top schematic view of an exemplary filter media pack 2100, illustrating a stacked configuration with two types of filter media. The filter media pack 2100 has two types of filter media: a first medium 2110 and a second medium 2120. The media pack 2100 has two layers of filter media 2110 alternating with one layer of media 2120.

FIG. 22 is a top partially schematic view of an exemplary filter media pack 2200 showing a stacked configuration with two types of filter media. The two types of filter media are first media 2210 and second media 2220. The media is shown in a stacked configuration, where the two types of filter media are mixed.

FIG. 23 is a schematic top portion view of an exemplary filter media pack 2300, showing a stacked configuration with three types of filter media. The three types of filter media are first media 2310, second media 2320, and third media 2330. The media is shown in a stacked configuration, with three types of filter media mixed.

Fig. 24A is a top schematic view of an exemplary filter media pack 2400, showing a coiled configuration with two types of filter media: a first media 2410 and a second media 2420. The media is shown in a rolled configuration, where the two types of media are distinguished from each other by laying down the filter media 2420 first and then laying down the filter media 2420 second. In this exemplary embodiment, the ratio of packet entry area 2420 to 2410 is about 2:1. This structure can be created by: for example, winding a first single facer media type over a period of time; cutting the roll and splicing the second single facer media type to an end region of the first single facer media type; continuing the winding process; and repeated for as many single-sided media types as desired. Alternatively, each winding of the single facer media type may be done separately, and the portions may be brought together and sealed as a secondary process.

FIG. 24B is a top schematic view of an exemplary filter media pack 2450 showing a coiled configuration with two types of flutes forming the filter media. The filter media pack 2540 has two types of flutes: a first medium 2460 and a second medium 2470. The media is shown in a coiled configuration with the two types of flutes separated from one another. In this exemplary embodiment, the ratio of the

packet entry areas

2470 and 2460 is about 2:1.

Fig. 25A is a top schematic view of an exemplary filter media pack 2500 illustrating a coiled configuration with three types of filter media: first medium 2510, second medium 2520, and third medium 2530. The media is shown in a rolled configuration, wherein the media are separated from each other by: filter medium 2520 is laid down first, and then second medium 2520 is laid down on top of medium 2510, and third medium 2530 is laid down on top of medium 2520. In this exemplary embodiment, the ratio of packet entry areas 2510 to 2520 to 2530 is about 4.

FIG. 25B is a top schematic view of an exemplary filter media pack 2550, showing a coiled configuration with three types of filter media. Filter media pack 2550 has first media 2560, second media 2670, and third media 2680. The media is shown in a rolled configuration, with three types of media separated from each other. In this exemplary embodiment, the ratio of packet entrance areas 2560 to 2570 to 2580 is about 4.

Fig. 26A is a top schematic view of an exemplary filter media pack 2600 showing a coiled configuration with two types of filter media. The filter media pack 2600 has two types of filter media: first media 2610 and second media 2620. The media is shown in a rolled configuration, where the two types of media are separated from each other by laying filter media 2620 first and then laying filter media 2620 onto the top of media 2610. In this exemplary embodiment, the ratio of

packet entry areas

2610 and 2620 is about 1:1.

Fig. 26B is a top schematic view of an exemplary filter media pack 2650, showing a coiled configuration with two types of filter media. The filter media pack 2540 has two types of filter media: a first medium 2660 and a second medium 2670. The media is shown in a rolled configuration, with the two types of media separated from each other. In this exemplary embodiment, the ratio of

packet entry areas

2660 and 2670 is approximately 1:1.

Aspects may be better understood with reference to the following examples, in which element a, element B, and element C are compared to one another. Element a consists entirely of medium a with a groove having a width of about 10.7 mm and a height of 3.2 mm and a tapered cross-sectional area. Element B consists entirely of medium B with grooves having a width of about 8.0 mm and a height of about 2.7 mm and a tapered area. The cell density per square centimeter of cell a was about 2.8 and cell B was about 4.4. Element C consists of 50% by volume of medium a and 50% by volume of medium B to form a mixed medium. Fig. 27 shows the load curves for a filter element made using media a, media B, and mixed media. The load curve shows the pressure loss of the filter element as the grams of dust increase from zero to less than 500 grams. As shown in FIG. 27, media B and the mixed media start at very similar restriction levels (approximately 2.5 inches H) ₂ 0) And media A has about 3.2 inches H ₂ A higher initial pressure loss of 0. As the dust begins to load, the pressure loss increases on all elements, however the pressure loss of media a and mixed media increases more slowly than media B, where the pressure losses of media a and media B cross (or are the same) at about 125 grams of dust. Thus, the mixed media closely tracks media B just beginning with the dust load, and then closely tracks media a as the dust load increases to a higher level. In other words, the mixed media has an initial limit similar to media B, but a load similar to media a.

To further test the improved filtration performance, a test stand was provided having a dual duct system of 5 to 9 cubic meters of air flow per minute configured to measure pressure loss and outlet restriction values. The relative performance of media elements formed using combinations of filter media was investigated by constructing various filter element designs. The elements are formed from z-flow media arranged in a stacked configuration. The elements each have an inlet face of 150 x 150 mm and an outlet face of 150 x 150 mm and a depth of 150 mm. The filter element is made of two types of media: medium a and medium B. Media slot configurations for Media a and Media B are consistent with those shown in U.S. patent No. 9,623,362 to scott M brown, inventor, and assigned to donnson limited, entitled Filtration Media Pack, filter element, and Air Filtration Media. Media a and B are predominantly cellulosic media. Media a had a slot height of about 0.092 inches, a slot width of about 0.314 inches, and a slot length (including slot plugs) of about 150 millimeters. Media B has a slot height of about 0.140 inches, a slot width of about 0.430 inches, and a slot length (including slot plugs) of about 150 millimeters. A first type of "segmented" media pack is an assembled pack of media a and media B positioned adjacent to each other in parallel flow. A second type of "layered" media pack comprises alternating sheets of media a and media B.

Fig. 28A-30B show performance results for various media configurations, including dust loading and pressure loss. Fig. 28A, 29A, and 30A show the results of the segmentation configuration (media a grouped together and all media B grouped together); and fig. 28B, 29B and 30B show the results of a layered structure (in which at least some of the medium a and the medium layer are mixed). Thus, the media construction includes either media a, media B, or media a and media B in various volume percentages. The media represented as 0% at the far left of each graph is without media a and is therefore entirely media B. The rightmost medium, denoted 100%, is medium a only and thus no medium B. The Y-axis contains the ISO fine dust loading measured in grams, and the pressure loss measured in inches of water.

Fig. 28A and 28B show performance results for various media constructions at a cubic flow rate of 5.83 cubic meters per minute, including dust loading and pressure loss. As can be seen from fig. 28A and 28B, the best performance, in particular the highest dust load, is achieved with the mixed media: the mixed media pack containing both media a and media B has a higher dust loading capacity than either media a or media B alone.

Fig. 29A and 29B show performance results for various media constructions at a cubic flow rate of 7.37 cubic meters per minute, including dust loading and pressure loss. Also, as in fig. 29A and 29B, the best performance is achieved with a mixed medium of medium a and medium B.

Fig. 30A and 30B show performance results for various media configurations at a cubic flow rate of 8.78 cubic meters per minute, including dust loading and pressure loss. As can be seen from fig. 30A and 30B, the best performance, in particular the highest dust load, is achieved again with the mixed media.

It should be noted that, as used in this specification and the appended claims, the singular forms "a," "an," and "the" include plural referents unless the content clearly dictates otherwise. Thus, for example, reference to a composition containing "a compound" includes mixtures of two or more compounds. It should also be noted that the term "or" is generally employed in its sense including "and/or" unless the content clearly dictates otherwise.

It should also be noted that, as used in this specification and the appended claims, the phrase "configured to" describes a system, device, or other structure that is constructed or arranged to perform a particular task or take a particular configuration. The phrase "configured to" may be used interchangeably with other similar phrases such as arranged and configured, constructed and arranged, constructed, manufactured and arranged, or the like.

Aspects have been described with reference to various specific and preferred embodiments and techniques. It should be understood, however, that many variations and modifications may be made within the spirit and scope herein.

The embodiments described herein are not intended to be exhaustive or to limit the invention to the precise forms disclosed in the following detailed description. Rather, the embodiments are chosen and described so that others skilled in the art may appreciate and understand the principles and practices.

All publications and patents mentioned herein are incorporated herein by reference. The publications and patents disclosed herein are provided solely for their disclosure. Nothing herein is to be construed as an admission that the inventors are not entitled to antedate any publication and/or patent, including any publication and/or patent cited herein.

Claims

1. An air filtration media pack comprising:

a first plurality of flutes of media and a second plurality of flutes of media, the first and second plurality of flutes disposed together within at least one layer of filter media and arranged in a parallel flow configuration;

wherein the first and second plurality of slots exhibit a difference in slot shape or slot size.

2. An air filtration media pack according to claim 1, wherein the flute cross-sectional area of the first plurality of flutes varies along the length of the flutes, and wherein the flute cross-sectional area of the second plurality of flutes varies along the length of the flutes.

3. An air filtration media pack according to claim 1, wherein the first and second plurality of flutes are tapered.

4. An air filtration media pack according to claim 3, wherein the first and second plurality of flutes are mirror images of each other.

5. An air filtration media pack according to claim 1, wherein the flow path through the media begins in one plane and the flow path through the media ends in a second plane.

6. An air filtration media pack according to claim 1, further comprising a third plurality of flutes disposed in parallel flow with the first and second plurality of flutes;

wherein the first, second, and third pluralities of slots exhibit differences in slot shape or slot size.

7. An air filtration media pack according to claim 1, wherein the first plurality of flutes constitute 40% to 60% of the volume of the air filtration media pack and the second plurality of flutes constitute 60% to 40% of the volume of the air filtration media pack.

8. An air filtration media pack according to claim 1, wherein the media is provided in a rolled configuration.

9. An air filtration media pack comprising:

a first plurality of flutes of media and a second plurality of flutes of media, the first plurality of flutes and the second plurality of flutes arranged in a parallel flow configuration;

wherein the first and second plurality of flutes exhibit differences in flute shape, flute size, flute height, flute width, flute cross-sectional area, or filter media; and

wherein the flow path through the medium starts in one plane and the flow path through the medium ends in a second plane.

10. An air filtration media pack according to claim 9, wherein the first and second plurality of flutes are tapered.

11. An air filtration media pack according to claim 10, wherein the first and second plurality of flutes are mirror images of each other.

12. An air filtration media pack according to claim 9, wherein the flow path through the media begins in one plane and the flow path through the media ends in a second plane.

13. An air filtration media pack according to claim 9, further comprising a third plurality of flutes disposed in parallel flow with the first and second plurality of flutes;

14. An air filtration media pack according to claim 9, wherein the first plurality of flutes constitute 40% to 60% of the volume of the air filtration media pack and the second plurality of flutes constitute 60% to 40% of the volume of the air filtration media pack.

15. An air filtration media pack according to claim 9, wherein the media is provided in a rolled configuration.

16. An air filtration media pack according to claim 9, wherein the difference in flutes is regular and repeating.

17. An air filtration media pack according to claim 9, wherein the first and second plurality of flutes are spliced together.